Hardfacing for Wear, Erosion and Abrasion

Abstract

Weld overlay coatings also known as hardfacing is a method which involves solidification for applied coatings. This method is as old as welding process and was first applied by J.W. Spencer in 1896. This technique offers unique advantages over other processes in that the overlay/substrate weld provides a metallurgical bond which is not susceptible to spallation and can easily be applied free of porosity and other defects. Weld deposits can have a thickness as high as 10 mm. Hardfacing process can be carried out easily even in on site. The process is also extremely versatile as a large variety of materials can be deposited for protection against degradation.Weld overlay coatings can be classified under four different categories. These are (1) surface cladding where a thick layer of materials is applied and the overlay layer can have completely different composition from the substrate, (2) hardfacing where a materials more resistant to degradation is applied with good metallurgical bonding and the composition can be close in terms of composition to that of the substrate, (3) build up where a weld deposit is applied to restore the original dimension of the component and the composition of the build layer is exactly similar to that of the substrate and (4) buttering where an intermediate layer is deposited before applying the final coating.The materials used for hardfacing should have melting point close to or lower than the substrate materials. During hardfacing, the temperature of the coating

Effects of Heat Treatment and Erosion Particle Size on Erosion Resistance of a Hypereutectic High-Chromium Cast Iron

“…HCCIs derive their properties from a chemical composition typically ranging from 2 to 7 wt.% C and 5 to 36 wt.% Cr [3]. HCCIs can be considered composite materials because their microstructure contains kinds of carbides such as M 23 C 6 , M 7 C 3 , and M 3 C 2 within a softer iron matrix that accounts for their outstanding performance (high hardness and wear resistance).…”

“…In industrial applications, a widely adopted solution to extend the service life of components in machinery equipment or implants involves the application of protective coatings to the most critical zones exposed to severe wear conditions (e.g., high operating temperatures, corrosive environments, mechanical damage by impact of solid particles) through welding techniques [1]. Among various surface coating and protective hardening techniques, hardfacing stands out due to its low cost and ease of handling [2][3][4]. Hardfacing enhances the corrosive, abrasive, and heat resistance properties of the surface by creating a cladding metal layer with improved features.…”

Reducing the wear and corrosion of the agricultural mower steel knives by electrodeposition nanocomposite coatings – Review

“…Hardfacing technique is a welding process used to deposit hard alloy to repairing, protective, and increasing lifetime of working parts. Hardfacing coating layer is a strong bond with substrate metal and this technique provides protection against corrosion with a maximum thickness of 10 mm [50][51][52] Hardfacing technique was used for enhancing excavator bucket teeth, tillage machines and mining tools against abrasive wear. Hardfacing layer thickness ranges from 2 mm to 3 mm with many passes [53].…”

A Comparative Study of Hardfacing Deposits Using a Modified Tribological Testing Strategy

“…Studies on the abrasive wear issues show that the use of a wide variety of hardfacing techniques can improve the performance of machinery and machinery components in an industry in an economical manner. Hardfacing is emerging as the most versatile method for depositing wear-resistant layers on a wide variety of materials [17,18]. Hardfacing is becoming increasingly important in improving the wear properties of carbon and low-alloy steels with carbon contents of less than 1%.…”